US20050261948A1 - Method and system for merging orders in a flexible order transaction system - Google Patents
Method and system for merging orders in a flexible order transaction system Download PDFInfo
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- US20050261948A1 US20050261948A1 US10/851,282 US85128204A US2005261948A1 US 20050261948 A1 US20050261948 A1 US 20050261948A1 US 85128204 A US85128204 A US 85128204A US 2005261948 A1 US2005261948 A1 US 2005261948A1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
- G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/02—Reservations, e.g. for tickets, services or events
- G06Q10/025—Coordination of plural reservations, e.g. plural trip segments, transportation combined with accommodation
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
- G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders
- G06Q10/0875—Itemisation or classification of parts, supplies or services, e.g. bill of materials
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q30/00—Commerce
- G06Q30/02—Marketing; Price estimation or determination; Fundraising
- G06Q30/0283—Price estimation or determination
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q99/00—Subject matter not provided for in other groups of this subclass
Definitions
- the present invention relates to a method and system for merging orders in a flexible order transaction system.
- the flexible order system relates to a shop floor manufacturing system controlling already in progress production orders.
- merging orders that are already in progress is possible but is limited in the way production is mapped between the merging order and in how scrap and work-in-process quantities are merged. For example, if a production process for the surviving order (i.e., the order remaining after the merge) involves 5 steps S 1 -S 5 and the production process for the merging order (i.e., the order that disappears after the merge) involves 10 steps M 1 -M 10 , the merging order may typically be merged with the surviving order at single pair of mapped steps (e.g., M 1 to S 3 ). This mapping may occur between reporting points for the steps.
- a reporting point is the conclusion of a discrete step in a production process where an accurate accounting of the progress of an order may be made.
- Reporting points may be used to define the steps in the production process and it is typically at one pair of reporting points that orders are merged.
- Scrap and work-in-process (WIP) quantities are also merged where they exist at the mapped reporting points.
- WIP work-in-process
- scrap and WIP is not merged in conventional systems where they occur at reporting points not mapped from the merging order to the surviving order—conventional systems are limited to merging scrap and WIP only at mapped reporting points, referred to as “hard merging” of the scrap and WIP.
- Conventional flexible order transaction systems do no provide the ability to merge in progress production orders at multiple reporting points across the production process. Even the merging that is allowed is limited to merging scrap and WIP at the mapped reporting points.
- merging orders in a flexible manner can greatly enhance efficiency. For example, orders that were previously split may need to be reassembled before shipment to another plant or production line where larger order sizes are more cost efficient. Merging orders may also solve unexpected capacity constraints in the production process. These enhancements may be achieved through a more detailed merging of orders allowing the merge to occur at several reporting points mapped between the processes of the orders. A more detailed method for the transfer of WIP from a merging order to a surviving order may also improve a flexible order transaction system.
- a method for merging an order with a surviving order in a flexible order transaction system where production of the order is currently in progress allows the production to be merged at multiple points in the production process overcoming some of the limitations of conventional systems.
- a request to merge the order only needs to specify the order to be merged and the surviving order.
- the quantity of successfully processed product i.e., the yield
- the quantity of unsuccessfully processed product that cannot be reprocessed i.e., the scrap
- the as of yet unprocessed product i.e., the work-in-process or WIP
- the WIP may include not only the as of yet unprocessed product but also unsuccessfully processed product that can be reprocessed (i.e., reworked) and/or the product that is currently being processed.
- the reporting points in the merging order are mapped to reporting points in the surviving order and the yield, scrap, and WIP at each mapped reporting point in the merging order are transferred to the corresponding mapped reporting point in the surviving order.
- the scrap and WIP at each unmapped reporting point in the merging order may also be transferred to the surviving order.
- the unmapped scrap and WIP may be transferred using the mapping at the first preceding (i.e., first earlier) mapped reporting point in the merging order in one embodiment of the present invention.
- the unmapped scrap and WIP may be transferred using the mapping at the first subsequent mapped reporting point in the merging order.
- the present invention allows the merging of an order with a surviving order to occur at multiple reporting points in a single merge order transaction.
- a merge order transaction may include the merging of production quantities (yield, scrap, and WIP) across multiple reporting points between several merging orders.
- the mapping between the process associated with the merging order and the process associated with the surviving order may already exist in a mapping table of the flexible order transaction system or may be specified during the merge order request in separate embodiments of the present invention.
- mapping does not need to be provided when orders are merged.
- unmapped scrap and WIP can be automatically determined by the system by using a “soft up” approach where the unmapped scrap and WIP may be merged at the first preceding mapped reporting point in one embodiment of the present invention.
- unmapped scrap and WIP may be merged at the next subsequent mapped reporting point using a “soft down” approach.
- FIG. 1 is a diagram illustrating the processing of an example production order before the order is merged according to one embodiment of the present invention.
- FIG. 2 is a diagram depicting the merge order process according to one embodiment of the present invention.
- FIG. 3 is a diagram illustrating the merging of three orders according to one embodiment of the present invention using a “soft down” approach to transferring unmapped quantities.
- FIG. 4 is a diagram illustrating the “soft up” process of merging WIP, scrap, and component and resource usage from unmapped reporting points at the first preceding mapped reporting point according to one embodiment of the present invention.
- orders may be merged allowing the transfer of production between several points in the production process of a merging order (i.e., the order that will be eliminated after the merge) to corresponding points in the production process of the surviving order (i.e., the order that will remain after the merge) according to one embodiment of the present invention.
- the merging of 2 or more orders results in only 1 remaining order (i.e., the surviving order).
- all orders are merging orders and a single surviving order is created with the same process structure (i.e., processing) as one of the merging orders.
- the merging orders may have a different structure and processing (i.e., process structure) from the surviving order.
- the processing or process structure is the actual work (i.e., processing) performed on the production inputs (i.e., the components) using the process resources (i.e., resources) to transform a product from components at the start of the process to a final product according to one embodiment of the present invention.
- the actual work (i.e., the processing or process structure) that is performed may differ between the merging order and the surviving order or may share the same process structure. If the process structure of the merging order is different from the surviving order, mapping between the processes as discussed below may be necessary.
- a merging order may be placed for a different final product than the surviving order.
- FIG. 1 is a diagram illustrating the processing of an example production order before the order is merged according to one embodiment of the present invention.
- the example embodiment shown in FIG. 1 depicts an order, Order_A, 100 for the production of 30 units of a product.
- a production process is the process needed to convert inputs (e.g., components and resources) into a product or to modify a manufactured item in order to produce a desired finished product.
- the inputs into the production process can be considered components, the physical items required to produce the product, and resources, the labor, machinery, and other services required to produce the product.
- inputs e.g., components and resources
- a production process may be divided in several discrete steps representing particularly distinct or distinguishable portions of the process at the conclusion of which an accurate accounting of the progress of an order may be made.
- a reporting point (RP) is the conclusion of one of these portions or steps in the production process and at which the status of the order may be confirmed.
- the order status may be determined by any conventional means including manual and automated reporting on order status.
- the production process associated with Order_A 100 includes four reporting points (RP): RP A 1 101 , RP A 2 102 , RP A 3 103 , and RP A 4 104 .
- each reporting point the inputs for the product are consumed as part of the shop floor production process according to one embodiment of the present invention.
- a unit of the product is either successfully processed—ending up as “yield”—or is unsuccessfully processed—ending up as “scrap”.
- Yield is the quantity of the product that has already been processed at an activity level reported on at the reporting point.
- Scrap is the quantity that at a given activity level (reporting point) will no longer be further processed.
- the remaining quantity still undergoing processing or still waiting for processing to initiate for the reporting point (RP) is considered the Work-in-Process (WIP) quantity.
- WIP Work-in-Process
- an unsuccessfully processed unit of the product can be reprocessed, it is considered WIP instead of scrap, which can't be reprocessed.
- an unsuccessfully processed unit of product at a reporting point is considered scrap if it can't be reprocessed while if it can be reprocessed, it is considered WIP and eventually reprocessed-scrap is not salvageable.
- the quantity of yield, scrap, and WIP equal the yield from the preceding reporting point according to one embodiment of the present invention.
- the quantities of yield, scrap, and WIP equal the order quantity according to this embodiment.
- Order_A 100 is placed for a quantity of 30 units of the product.
- the quantity of yield, scrap, and WIP equal the 30 units for the order.
- the quantity of yield at RP A 1 101 is 24 units 111 while the quantity of scrap is 3 units 121 and the quantity of WIP is 3 units 141 totaling the 30 units for the order 100 .
- the second reporting point, the quantity of yield, scrap, and WIP need to equal the 24 units of yield 111 at the preceding RP A 1 according to this embodiment of the present invention.
- the quantity of yield at RP A 2 102 is 18 units 112 while the quantity of scrap is 2 units 122 and the quantity of WIP is 4 units 142 totaling the 24 units of yield 111 at RP A 1 101 .
- the yield quantity at the final reporting point in a production process represents the total quantity of the finished product produced so far and may be the reporting point at which the ordered goods are received.
- the final reporting point shown in FIG. 1 is reporting point A 4 104 .
- the quantity of yield is 13 units 114 representing the total quantity of the finished product produced up to this point.
- an order 100 is placed for a quantity of 30 of a product.
- the process for Order_A includes four reporting points in the example shown in FIG. 1 .
- 24 units 111 of the product have been successfully processed and are considered yield at this reporting point.
- Three units 121 have been unsuccessfully processed and can't be reworked (i.e., reprocessed) and have become scrap at this reporting point.
- a remaining 3 units 141 of the product have yet to begin or complete the production process up to reporting point A 1 and are consider WIP. Components and resources are used in the processing occurring up to RP A 1 101 .
- FIG. 1 In the example embodiment in FIG.
- reporting point (RP) A 3 103 only 14 units 113 of the 18 units 112 of the product yielded at RP A 2 102 have been successfully processed and have become yield.
- One unit 123 has been unsuccessfully processed and can't be reworked (i.e., reprocessed) and, therefore, is now scrap at RP A 3 103 .
- Three units 143 remain to be processed or to complete processing at RP A 3 103 and are considered WIP.
- the quantity of components (C 3 ) and resources (R 3 ) used for the processing to reporting point A 3 103 each equal 15 units 133 for the units of yield 113 and scrap 123 that have been processed.
- a quantity of 30 units 100 is ordered with 13 units 114 of final product produced at RP A 4 104 .
- the successfully processed yield throughout the process includes 24 units 111 at RP A 1 101 , 18 units 112 at RP A 2 102 , 14 units 113 at RP A 3 103 , and 13 units 114 at RP A 4 104 .
- FIG. 2 is a diagram depicting the merge order process according to one embodiment of the present invention.
- the first step in the process for merging orders is to “Receive Request to Merge Orders” 201 .
- the request may be received in any number of ways according to various embodiments of the present invention.
- the request is received from the customer placing the order through a flexible order transaction system, a software application allowing flexible orders to be placed including the merging of production orders already in progress.
- the request to merge the orders does not need to specify the quantity to be merged and may only need to specify the merging order and the surviving order.
- the quantity to be merged can be determined from the merging order even though it may be specified in the merge order request.
- the merge order process described herein can be used to transfer partial quantity from a merging order with a surviving order, the merging order continuing to exist after the partial quantity is transferred.
- the user e.g., the customer
- the quantities for each reporting point of the merging order are determined.
- the yield, scrap, and work-in-process (WIP) are calculated at each reporting point in the process for the merging order. For example, using the information provided in FIG. 1 where Order_A is a merging order, reporting points A 1 -A 4 101 - 104 exist for the process used to implement Order_A.
- reporting point A 1 1101 the following quantities of the product are determined: 24 units of yield 111 , 3 units of scrap 121 , and 3 units of WIP 141 all equaling the 30 units 100 requested in the original order.
- the following quantities of the product are determined: 18 units of yield 112 , 2 units of scrap 122 , and 4 units of WIP 123 all equaling the 24 units of yield 111 ready for further processing after RP A 1 101 .
- the following quantities of the product are determined: 14 units of yield 113 , 1 unit of scrap 123 , and 3 units of WIP 143 all equaling the 18 units of yield 112 ready for further processing after RP A 2 102 .
- mapping data between the reporting points of the processes corresponding to the merging order(s) (e.g., Order_B) and the surviving order (e.g., Order_A) is determined.
- the mapping data may be determined in different ways according to various embodiments of the present invention.
- the mapping data may be determined by retrieving mapping data already stored for the processes. For example, data from a mapping table containing the reporting point mapping between the processes associated with the merging order, e.g., Order_B, and the surviving order, e.g., Order_A, may be retrieved.
- a user may specify the mapping data when the merging of the orders is requested.
- reporting points B 1 , B 3 , and B 6 in the merging order correspond to reporting points A 1 , A 2 , and A 4 respectively in the surviving order.
- the mapping data may be calculated using other variables to determine at which reporting points similar processing has occurred.
- the mapping data does not need to include mapping from all the reporting points in the process associated with the merging order to corresponding reporting points in the process associated with the surviving order, according to this embodiment—though all reporting points may be mapped.
- the mapping between a merging order, e.g., Order_B, with associated reporting points B 1 -B 6 may only map 3 of the reporting points (e.g., B 1 , B 3 , and B 6 ) with a surviving order, e.g., Order_A.
- all the reporting points in the process associated with the merging order do not need to be mapped, all the reporting points in the process associated with the surviving order also do not need to be mapped to the merging order.
- a surviving order e.g., Order_A
- reporting points A 1 -A 4 may only have 3 reporting points mapped to the merging order, e.g., Order_C.
- two or more reporting points associated with a merging order e.g., Order_D
- a single reporting point associated with a surviving order e.g., Order_A. This may occur where the additional processing for the second reporting point in the merging order (e.g., Order_D) does not add anything above the processing for the first reporting point in the merging order in relation to the processing that needs to occur in the surviving order (e.g., Order_A).
- reporting points D 2 and D 3 associated with a merging order, Order_D may be mapped to a single reporting point A 3 associated with a surviving order, Order_A.
- a single reporting point associated with a merging order e.g., Order_E
- two or more reporting points associated with a surviving order e.g., Order_A
- reporting point E 3 associated with a merging order, Order_E may be mapped to reporting points A 3 and A 4 associated with a surviving order, Order_A.
- Any conventional mapping means may be used to determine and supply the mapping data required.
- yield i.e., the successfully processed units
- scrap i.e., the unsuccessfully processed units that can't be reworked
- WIP i.e., units awaiting or undergoing processing
- Yield, scrap, and WIP are therefore transferred between the mapped reporting point pairs: RP B 1 -RP A 1 , RP B 3 -RP A 2 , and RP B 6 -RP A 4 .
- the component and resource usage for the yield and scrap transferred at the mapped reporting points is also transferred to the surviving order.
- WIP, scrap, and the component and resource usage from non-mapped reporting points in the merging order are also transferred to the surviving order (e.g., Order_A) at the next mapped reporting point according to one embodiment in the present invention.
- This embodiment is a “soft down” transfer of unmapped quantities of WIP and scrap. If there are no further mapped reporting points between the merging and surviving orders, the non-mapped quantities are transferred to the last reporting point in the surviving order according to one embodiment of the present invention.
- WIP, scrap, and the component and resource usage from non-mapped reporting points in the merging order are transferred to the surviving order at the next preceding mapped reporting point in the production process.
- This alternative embodiment is a “soft up” transfer of unmapped quantities of WIP and scrap. If there are no preceding mapped reporting points between the merging and surviving orders, the non-mapped quantities are transferred to the first reporting in the surviving order according to one embodiment of the present invention.
- the steps described above are illustrative of the process and they can be performed in a different sequence, as necessary.
- the steps of “Merge Mapped Quantities” 204 and “Merge Unmapped Quantities” 205 can be performed simultaneously or in sequence for each of the reporting points between a merging order and the surviving order.
- all the existing orders may be considered merging orders with a new surviving order created matching the process structure of one of the merging orders and receiving the yield, scrap, and WIP from the merging orders.
- FIG. 3 is a diagram illustrating the merging of three orders according to one embodiment of the present invention.
- two merging orders Order_B 300 b and Order_C 300 c
- the surviving Order_A 300 a , 300 m was originally placed for a quantity of 10 units 300 a before the merging of the orders.
- the merging of the orders combines their placed quantities creating a post-merge quantity of 30 units 300 m in the surviving order 300 m .
- the original order quantities and the resulting post-merge surviving order quantity are reflected as follows: Original (Pre-Merge) Resulting (Post-Merge) Order Quantity Order Quantity Order_A 10 30 Order_B 10 — Order_C 10 — According to the example shown in FIG. 3 , yield, scrap, and WIP are transferred from the merging orders, Order_B 300 b and Order_C 300 c , to the surviving order, Order_A 300 m . In an alternative embodiment, a new surviving order is created and all the original orders are merged into the new order and then deleted.
- the implementation of the merge according to the embodiment depicted in FIG. 3 depends on the mapping between reporting points of the orders and is outlined below.
- yield, scrap, and WIP are transferred from the merging orders, Order_B 300 b and Order_C 300 c , to the surviving Order_A 300 a , 300 m .
- the yield, scrap, and WIP are transferred according to the mapping between the reporting points associated with the merging orders, Order_B 300 b and Order_C 300 c , and the reporting points associated with the surviving Order_A 300 a , 300 m .
- At reporting point B 1 351 7 units of successfully processed yield 361 , 2 units of unsuccessfully process scrap 361 s (which can't be reprocessed), and 1 unit of work-in-process (WIP) 361 w are available.
- the yield 361 , scrap 361 s , and WIP 361 w at RP B 1 351 equal the total order quantity 300 b of 10 units for Order_B.
- Reporting point B 1 351 maps to reporting point A 1 301 in the surviving order.
- 8 units of yield 311 p , 1 unit of scrap 321 p , and 1 unit of WIP 331 p exist before the merge (i.e., pre-merge).
- This yield 311 p , scrap 321 p , and WIP 331 p at RP A 1 301 equal the total order quantity 300 a of 10 units for Order_A before the merge.
- all quantities are transferred from the merging order to the surviving order at the mapped reporting points.
- a yield of 7 units 361 , a scrap of 2 units 361 s , and a WIP of 1 unit 361 w at RP B 1 351 are transferred to RP A 1 301 and added to the yield 311 m , scrap 321 m , and WIP 331 m .
- the component (BC 1 and resource (BR 1 ) usage 361 c at RP B 1 351 is also transferred to RP A 1 301 .
- Reporting point B 2 352 has a yield of 6 units 362 , a scrap of 1 unit 362 s , and a WIP of 0 units 362 w but is not mapped to Order_A 300 a , 300 m .
- the yield 362 , scrap 362 s , and WIP 362 w at RP B 2 352 equal the yield of 7 units 361 from the previous reporting point RP B 1 351 .
- Reporting point B 3 353 has a yield of 5 units 363 , a scrap of 0 units 363 s , and a WIP of 1 unit 363 w equaling the yield of 6 units 362 at the previous reporting point RP B 2 352 .
- RP B 3 353 is mapped to RP A 2 302 of Order_A 300 a , 300 m and, therefore, the yield 363 , scrap 363 s , and WIP 363 w are transferred and added to the existing pre-merge yield of 6 units 312 p , scrap of 0 units 322 p , and WIP of 2 units 332 p at RP A 2 302 .
- the scrap 362 s and WIP 362 w of any unmapped preceding reporting points (in this case RP B 2 352 ) are also transferred.
- an additional scrap of 1 unit 362 s and a WIP of 0 units 362 w is also transferred from RP B 2 352 at the next mapped reporting RP B 3 353 to RP A 2 302 .
- Unmapped yield is not transferred according to this embodiment, only unmapped scrap and WIP.
- the component (B 3 ) and resource (BR 3 ) usage 363 c at the mapped reporting point 353 and component (BC 2 ) and resource (BR 2 ) usage 362 c at any preceding unmapped reporting point 352 are also transferred to RP A 2 302 .
- Reporting point B 4 354 has a yield of 5 units 364 , a scrap of 0 units 364 s , and a WIP of 0 units 364 w totaling the 5 units of yield 363 at the previous RP B 3 353 .
- RP B 4 354 is not mapped to Order_A 300 a , 300 m .
- Reporting point B 5 355 has a yield of 4 units 365 , a scrap of 1 unit 365 s , and a WIP of 0 units 365 w totaling the 5 units of yield 364 at the previous RP B 4 354 .
- RP B 5 355 is not mapped to Order_A 300 a , 300 m .
- Reporting point B 6 356 has a yield of 3 units 366 , a scrap of 0 units 366 s , and a WIP of 1 unit 366 w totaling the 4 units of yield 365 at the previous RP B 5 355 .
- RP B 6 356 is mapped to RP A 4 304 in Order_A 300 a , 300 m and, therefore, its yield 366 , scrap 366 s , and WIP 366 w are transferred and added to the yield of 2 units 314 p , scrap of 0 units 324 p , and WIP of 2 units 334 p that exist at RP A 4 304 prior to the merge.
- preceding unmapped scrap and WIP are also transferred according to this embodiment of the present invention.
- the other merging order is Order_C 300 c .
- RP C 1 381 is not mapped to the surviving Order_A 300 a , 300 m .
- Reporting point C 2 382 has a yield of 6 units 392 , a scrap of 1 unit 392 s , and a WIP of 2 units 392 w totaling the yield 391 of 9 units at the preceding RP C 1 381 .
- RP C 2 382 is mapped to RP A 1 301 and, therefore, the yield 392 , scrap 392 s , and WIP 392 w are transferred and added to RP A 1 301 .
- any preceding unmapped scrap and WIP are also transferred according to this embodiment.
- the scrap of 1 unit 391 s and no WIP 391 w (0 units) are also transferred from RP C 1 381 to RP A 1 301 .
- the component (CC 2 ) and resource (CR 2 ) usage 392 c from the mapped reporting point 382 and the component (CC 1 ) and resource (CR 1 ) usage 391 c from any unmapped preceding reporting points 381 are also transferred to RP A 1 301 .
- Reporting point C 3 383 has a yield of 5 units 393 , a scrap of 1 unit 393 s , and a WIP of 0 units 393 w totaling the yield of 6 units 392 at the preceding RP C 2 382 .
- RP C 3 383 is not mapped to the surviving Order_A 300 a , 300 m .
- Reporting point C 4 384 has a yield of 4 units 394 , a scrap of 0 units 394 s , and a WIP of 1 unit 394 w totaling the 5 units of yield 393 at the preceding RP C 3 383 .
- RP C 4 384 is mapped to RP A 3 303 and, therefore, the yield 394 , scrap 394 s , and WIP 394 w are transferred.
- the scrap (1 unit 393 s ) and WIP (0 units 393 w ) from any preceding unmapped reporting points 383 are also transferred—in this case from RP C 3 383 .
- the component (CC 4 , CC 3 ) and resource (CR 4 , CR 3 ) usage 394 c , 393 c from the mapped reporting point 384 and any preceding unmapped reporting points 383 are also transferred to RP A 3 303 .
- Reporting point C 5 385 has yield of 4 units 395 , a scrap of 0 units 395 s , and a WIP of 0 units 395 w totaling the yield of 4 units 394 at the preceding RP C 4 394 .
- RP C 5 385 is not mapped to the surviving Order_A 300 a , 300 m .
- Reporting point C 6 386 has a yield of 1 unit 396 , no S scrap 396 s , and a WIP of 3 units 396 w totaling the yield of 4 units 395 at the preceding RP C 5 385 .
- RP C 6 386 is mapped to RP A 4 304 and, therefore, the yield 396 , scrap 396 s , and WIP 396 w are transferred.
- the scrap (0 units 395 s ) and the WIP (0 units 395 w ) from any preceding unmapped reporting points 385 are also transferred—in this case from RP C 5 385 .
- Component (CC 6 , CC 5 ) and resource (CR 6 , CR 5 ) usage 396 c , 395 c from the mapped reporting point 386 and any preceding unmapped reporting points 385 are also transferred to RP A 4 304 .
- the end result of the merging process is that all the yield, scrap, WIP, and component and resource usage is transferred from the merging orders to the surviving order according to one embodiment of the present invention.
- the original pre-merge yield of 8 units 31 p is increased by 7 units 361 from RP B 1 351 and 6 units 392 from RP C 2 382 resulting in a post-merge yield of 21 units 311 m .
- the pre-merge scrap of 1 unit 321 p is increased by the 2 units 361 s from RP B 1 351 , 1 unit 392 s from RP C 2 382 , and 1 unit 391 s from RP C 1 381 resulting in a post-merge scrap of 5 units 321 m .
- the pre-merge WIP of 1 unit 331 p is increased by 1 unit 361 w from RP B 1 351 , 2 units 392 w from RP C 2 382 , and 0 units 391 w from RP C 1 381 resulting in a post-merge WIP of 4 units 331 m .
- Component and resource usage 361 c , 392 c , 391 c is transferred from RP B 1 351 , RP C 2 382 , and RP C 1 381 and added to the component (AC 1 ) and resource (AR 1 ) usage 341 at RP A 1 301 .
- the pre-merge yield of 6 units 312 p is increased by 5 units 363 from RP B 3 353 . Because there is no mapping between RP A 2 302 and merging Order_C 300 c , the previously transferred yield of 6 units 392 continues at RP A 2 302 for the merged Order_C 300 c according to one embodiment of the present invention. The end result is a post-merge yield of 17 units 312 m .
- the pre-merge scrap of 0 units 322 p is increased by 0 units 363 s from RP B 3 353 and 1 unit 362 s from RP B 2 352 resulting in a post-merge scrap of 1 unit 322 m .
- Order_C 300 c does not map to RP A 2 302 and does not, therefore, alter the scrap or WIP at RP A 2 302 .
- the pre-merge WIP of 2 units 332 p is increased by 1 unit 363 w from RP B 3 353 and 0 units 362 w from RP B 2 352 resulting in a post-merge WIP of 3 units 332 m .
- Component and resource usage 363 c , 362 c is transferred from RP B 3 353 and RP B 2 352 and added to the component (AC 2 ) and resource (AR 2 ) usage 342 at RP A 2 302 .
- the pre-merge yield of 4 units 313 p is increased by 4 units 394 from RP C 4 384 . Because there is no mapping between RP A 3 303 and merging Order_B 300 b , the previously transferred yield of 5 units 363 from RP B 3 353 continues at RP A 3 303 for the merged Order_B 300 b according to one embodiment of the present invention. The end result is a post-merge yield of 13 units 313 m .
- the pre-merge scrap of 1 unit 323 p is increased by 0 units 394 s from RP C 4 384 and 1 unit 393 s from RP C 3 383 resulting in a post-merge scrap of 2 units 323 m .
- Order_B 300 b does not map to RP A 3 303 and does not, therefore, alter the scrap or WIP at RP A 3 303 .
- the pre-merge WIP of 1 unit 333 p is increased by 1 unit 394 w from RP C 4 384 and 0 units 393 w from RP C 3 383 resulting in a post-merge WIP of 2 units 333 m .
- Component and resource usage 394 c , 393 c is transferred from RP C 4 384 and RP C 3 383 and added to the component (AC 3 ) and resource (AR 3 ) usage 343 at RP A 3 303 .
- the pre-merge yield of 2 units 314 p is increased by 3 units 366 from RP B 6 356 and 1 unit 396 from RP C 6 386 resulting in a post-merge yield of 6 units 314 m .
- the pre-merge scrap of 0 units 324 p is increased by 0 units 366 s from RP B 6 356 , 1 unit 365 s from RP B 5 355 , 0 units 364 s from RP B 4 354 , 0 units 396 s from RP C 6 386 , and 0 units 395 s from RP C 5 385 resulting in a post-merge scrap of 1 unit 324 m .
- the pre-merge WIP of 2 units 334 p is increased by 1 unit 366 w from RP B 6 356 , 0 units 365 w from RP B 5 365 , 0 units 364 w from RP B 4 364 , 3 units 396 w from RP C 6 386 , and 0 units 395 w from RP C 5 385 resulting in a post-merge WIP of 6 units 334 m .
- Component and resource usage 366 c , 365 c , 364 c , 396 c , 395 c is transferred from RP B 6 356 , RP B 5 355 , RP B 4 354 , RP C 6 386 , and RP C 5 385 and added to the component (AC 4 ) and resource (AR 4 ) usage 344 at RP A 4 304 .
- the order quantity may be reduced during the merging process. For example, if the merging orders and the pre-merge surviving order have a total placed order quantity of 30, the resulting surviving order may be placed for a quantity less than 30. The decreased quantity may result from eliminating WIP or reducing order quantity to reflect scrap at the initial reporting point in the surviving order.
- scrap, WIP, and component and resource usage from unmapped reporting points in the merging orders were transferred to the surviving order at the next or subsequent mapped reporting point.
- This process may be referred to as “soft down” merging.
- scrap, WIP, and/or component and resource usage may be merged with the surviving order at the final reporting point in the surviving order.
- WIP, scrap, and/or component and resource usage at an unmapped reporting point may be merged with the surviving order at the first earlier or preceding mapped reporting point.
- WIP, scrap, and/or component and resource usage may be merged with the surviving order at the first reporting point in the surviving order. This process may be referred to as “soft up” merging.
- the merging of WIP, scrap, and/or component and resource usage at the final reporting point in a merging order is always made to the final reporting point in the surviving order regardless of whether “soft up” or “soft down” merging is being used.
- FIG. 4 is a diagram illustrating the process of merging WIP, scrap, and component and resource usage from unmapped reporting points at the first preceding mapped reporting point according to one embodiment of the present invention.
- the example embodiment shown in FIG. 4 is similar to the example shown in FIG. 3 except that the unmapped reporting point values in Order_B 300 b and Order_C 300 c are merged with the preceding mapped reporting points (or the first reporting point) thereby changing the post-merge yield, scrap, and WIP values in the surviving Order_A 300 m as well as the distribution of component and resource usage.
Abstract
Description
- The present invention relates to a method and system for merging orders in a flexible order transaction system. In one embodiment of the present invention, the flexible order system relates to a shop floor manufacturing system controlling already in progress production orders.
- In conventional flexible order transaction systems in manufacturing, merging orders that are already in progress is possible but is limited in the way production is mapped between the merging order and in how scrap and work-in-process quantities are merged. For example, if a production process for the surviving order (i.e., the order remaining after the merge) involves 5 steps S1-S5 and the production process for the merging order (i.e., the order that disappears after the merge) involves 10 steps M1-M10, the merging order may typically be merged with the surviving order at single pair of mapped steps (e.g., M1 to S3). This mapping may occur between reporting points for the steps. A reporting point is the conclusion of a discrete step in a production process where an accurate accounting of the progress of an order may be made. Reporting points may be used to define the steps in the production process and it is typically at one pair of reporting points that orders are merged. Scrap and work-in-process (WIP) quantities are also merged where they exist at the mapped reporting points. However, scrap and WIP is not merged in conventional systems where they occur at reporting points not mapped from the merging order to the surviving order—conventional systems are limited to merging scrap and WIP only at mapped reporting points, referred to as “hard merging” of the scrap and WIP. Conventional flexible order transaction systems do no provide the ability to merge in progress production orders at multiple reporting points across the production process. Even the merging that is allowed is limited to merging scrap and WIP at the mapped reporting points.
- Conventional flexible order transaction systems incorporate order merge functionality for production orders but do not provide for the detailed merging of orders at multiple reporting points across the production process. For example, the Oracle® Shop Floor Management 11i system is one example of a conventional flexible order transaction system. The SAP® Discrete Industry add-on is another example and incorporates order merge functionality for process orders. Additionally, these conventional systems limit the merging of work-in-process (WIP) to mapped reporting points between the merging and surviving order.
- Providing greater flexibility in merging already in progress production orders is important for a number a reasons. This flexibility can help manufacturers who often need to bring an order or lot up to an efficient production order size. When several orders have dropped below the target order size due to scrap (i.e., unsuccessfully processed product) or splits (i.e., order splitting) or when subsequent steps in a production process are more efficient with larger order sizes, merging orders in a flexible manner can greatly enhance efficiency. For example, orders that were previously split may need to be reassembled before shipment to another plant or production line where larger order sizes are more cost efficient. Merging orders may also solve unexpected capacity constraints in the production process. These enhancements may be achieved through a more detailed merging of orders allowing the merge to occur at several reporting points mapped between the processes of the orders. A more detailed method for the transfer of WIP from a merging order to a surviving order may also improve a flexible order transaction system.
- In one embodiment of the present invention, a method for merging an order with a surviving order in a flexible order transaction system where production of the order is currently in progress allows the production to be merged at multiple points in the production process overcoming some of the limitations of conventional systems. According to one embodiment, a request to merge the order only needs to specify the order to be merged and the surviving order. At each reporting point in the process for the merging order, the quantity of successfully processed product (i.e., the yield), the quantity of unsuccessfully processed product that cannot be reprocessed (i.e., the scrap), and the as of yet unprocessed product (i.e., the work-in-process or WIP) are determined. In another embodiment, the WIP may include not only the as of yet unprocessed product but also unsuccessfully processed product that can be reprocessed (i.e., reworked) and/or the product that is currently being processed. The reporting points in the merging order are mapped to reporting points in the surviving order and the yield, scrap, and WIP at each mapped reporting point in the merging order are transferred to the corresponding mapped reporting point in the surviving order. The scrap and WIP at each unmapped reporting point in the merging order may also be transferred to the surviving order. The unmapped scrap and WIP may be transferred using the mapping at the first preceding (i.e., first earlier) mapped reporting point in the merging order in one embodiment of the present invention. In another embodiment, the unmapped scrap and WIP may be transferred using the mapping at the first subsequent mapped reporting point in the merging order. The present invention allows the merging of an order with a surviving order to occur at multiple reporting points in a single merge order transaction. For example, using the SAP® Flexible Order Transaction in the Advanced Planning and Optimization (APO), a merge order transaction may include the merging of production quantities (yield, scrap, and WIP) across multiple reporting points between several merging orders. The mapping between the process associated with the merging order and the process associated with the surviving order may already exist in a mapping table of the flexible order transaction system or may be specified during the merge order request in separate embodiments of the present invention. Even where a user specifies mapping, the user does not have to specify all the mapping between reporting points in the merging and surviving orders as may be required in conventional systems. Additionally, detail mapping does not need to be provided when orders are merged. For example, where to merge unmapped scrap and WIP can be automatically determined by the system by using a “soft up” approach where the unmapped scrap and WIP may be merged at the first preceding mapped reporting point in one embodiment of the present invention. In another embodiment, under these same circumstances, unmapped scrap and WIP may be merged at the next subsequent mapped reporting point using a “soft down” approach.
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FIG. 1 is a diagram illustrating the processing of an example production order before the order is merged according to one embodiment of the present invention. -
FIG. 2 is a diagram depicting the merge order process according to one embodiment of the present invention. -
FIG. 3 is a diagram illustrating the merging of three orders according to one embodiment of the present invention using a “soft down” approach to transferring unmapped quantities. -
FIG. 4 is a diagram illustrating the “soft up” process of merging WIP, scrap, and component and resource usage from unmapped reporting points at the first preceding mapped reporting point according to one embodiment of the present invention. - In a flexible order transaction system, orders may be merged allowing the transfer of production between several points in the production process of a merging order (i.e., the order that will be eliminated after the merge) to corresponding points in the production process of the surviving order (i.e., the order that will remain after the merge) according to one embodiment of the present invention. The merging of 2 or more orders (i.e., the surviving order and 1 or more merging orders) results in only 1 remaining order (i.e., the surviving order). In an alternative embodiment, all orders are merging orders and a single surviving order is created with the same process structure (i.e., processing) as one of the merging orders. In one embodiment of the present invention, the merging orders may have a different structure and processing (i.e., process structure) from the surviving order. The processing or process structure is the actual work (i.e., processing) performed on the production inputs (i.e., the components) using the process resources (i.e., resources) to transform a product from components at the start of the process to a final product according to one embodiment of the present invention. The actual work (i.e., the processing or process structure) that is performed may differ between the merging order and the surviving order or may share the same process structure. If the process structure of the merging order is different from the surviving order, mapping between the processes as discussed below may be necessary. In another embodiment of the present invention, a merging order may be placed for a different final product than the surviving order.
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FIG. 1 is a diagram illustrating the processing of an example production order before the order is merged according to one embodiment of the present invention. The example embodiment shown inFIG. 1 depicts an order, Order_A, 100 for the production of 30 units of a product. A production process, according to one embodiment of the present invention, is the process needed to convert inputs (e.g., components and resources) into a product or to modify a manufactured item in order to produce a desired finished product. The inputs into the production process can be considered components, the physical items required to produce the product, and resources, the labor, machinery, and other services required to produce the product. In the example embodiment shown inFIG. 1 , a production process may be divided in several discrete steps representing particularly distinct or distinguishable portions of the process at the conclusion of which an accurate accounting of the progress of an order may be made. A reporting point (RP) is the conclusion of one of these portions or steps in the production process and at which the status of the order may be confirmed. The order status may be determined by any conventional means including manual and automated reporting on order status. In the embodiment shown inFIG. 1 , the production process associated withOrder_A 100 includes four reporting points (RP): RP A1 101, RP A2 102, RP A3 103, and RP A4 104. - At each reporting point (RP), the inputs for the product are consumed as part of the shop floor production process according to one embodiment of the present invention. At each reporting point, a unit of the product is either successfully processed—ending up as “yield”—or is unsuccessfully processed—ending up as “scrap”. Yield is the quantity of the product that has already been processed at an activity level reported on at the reporting point. Scrap is the quantity that at a given activity level (reporting point) will no longer be further processed. The remaining quantity still undergoing processing or still waiting for processing to initiate for the reporting point (RP) is considered the Work-in-Process (WIP) quantity. According to one embodiment of the present invention, if an unsuccessfully processed unit of the product can be reprocessed, it is considered WIP instead of scrap, which can't be reprocessed. In other words, according to this embodiment, an unsuccessfully processed unit of product at a reporting point is considered scrap if it can't be reprocessed while if it can be reprocessed, it is considered WIP and eventually reprocessed-scrap is not salvageable.
- At each reporting point, the quantity of yield, scrap, and WIP equal the yield from the preceding reporting point according to one embodiment of the present invention. At the first reporting point, the quantities of yield, scrap, and WIP equal the order quantity according to this embodiment. For example in
FIG. 1 ,Order_A 100 is placed for a quantity of 30 units of the product. Atreporting point A1 101, the first reporting point, the quantity of yield, scrap, and WIP equal the 30 units for the order. The quantity of yield atRP A1 101 is 24units 111 while the quantity of scrap is 3units 121 and the quantity of WIP is 3units 141 totaling the 30 units for theorder 100. Atreporting point A2 102, the second reporting point, the quantity of yield, scrap, and WIP need to equal the 24 units ofyield 111 at the preceding RP A1 according to this embodiment of the present invention. The quantity of yield atRP A2 102 is 18units 112 while the quantity of scrap is 2units 122 and the quantity of WIP is 4units 142 totaling the 24 units ofyield 111 atRP A1 101. The yield quantity at the final reporting point in a production process represents the total quantity of the finished product produced so far and may be the reporting point at which the ordered goods are received. For example, the final reporting point shown inFIG. 1 is reportingpoint A4 104. AtRP A4 104, the quantity of yield is 13units 114 representing the total quantity of the finished product produced up to this point. - In the example shown in the embodiment in
FIG. 1 , anorder 100, Order_A, is placed for a quantity of 30 of a product. The process for Order_A includes four reporting points in the example shown inFIG. 1 . Atreporting point A 1101, 24units 111 of the product have been successfully processed and are considered yield at this reporting point. Threeunits 121 have been unsuccessfully processed and can't be reworked (i.e., reprocessed) and have become scrap at this reporting point. A remaining 3units 141 of the product have yet to begin or complete the production process up to reporting point A1 and are consider WIP. Components and resources are used in the processing occurring up toRP A1 101. In the example embodiment inFIG. 1 , 1 unit of component and 1 unit of resource are used per unit processed. Atreporting point A1 101, the quantity of components (C1) and resources (R1) used each equal 27units 131 for the units ofyield 111 and scrap 121 that have been processed. - Of the 24 units of
yield 111 atRP A1 units 112 of the product have been successfully processed and are considered yield atreporting point A2 102. Twounits 122 have been unsuccessfully processed and can't be reworked (i.e., reprocessed) and are scrap atRP A2 102. Fourunits 142 of the product (out of the 24 111) remain to be processed or to complete processing and are WIP atRP A2 102. The quantity of components (C2) and resources (R2) used for the processing toreporting point A2 102 each equal 20units 132 for the units ofyield 112 and scrap 122 that have been processed. - At reporting point (RP)
A3 103, only 14units 113 of the 18units 112 of the product yielded atRP A2 102 have been successfully processed and have become yield. Oneunit 123 has been unsuccessfully processed and can't be reworked (i.e., reprocessed) and, therefore, is now scrap atRP A3 103. Threeunits 143 remain to be processed or to complete processing atRP A3 103 and are considered WIP. The quantity of components (C3) and resources (R3) used for the processing toreporting point A3 103 each equal 15units 133 for the units ofyield 113 and scrap 123 that have been processed. - Of the 14
units 113 of the product yielded (i.e., successfully processed) atRP A3 units 114 have been successfully processed (are yield) atRP A4 104. BecauseRP A4 104 is the final reporting point, the 13units 114 of yield atRP A4 104 are finished products of the process A1-A4 forOrder_A 100 according to this embodiment of the present invention. There is noscrap 124 atRP A4 104 and the remaining oneunit 144 is WIP at this reporting point. The quantity of components (C4) and resources (R4) used for the processing toreporting point A4 104 each equal 13units 134 for the units ofyield 114 and scrap 124 that have been processed. - According to the example depicted in
FIG. 1 , a quantity of 30units 100 is ordered with 13units 114 of final product produced atRP A4 104. The successfully processed yield throughout the process includes 24units 111 atRP A1 units 112 atRP A2 units 113 atRP A3 units 114 atRP A4 104. Of the quantity of 30units units 121 atRP A1 units 122 atRP A2 unit 123 atRP A3 103, andnone 124 atRP A4 104. Of the quantity of 30 ordered, 11 units remain as WIP at the various reporting points: 3 units at RP A1, 4 units at RP A2, 3 units at RP A3, and 1 unit at RP A4. The example represented inFIG. 1 indicates that only the WIP remains to be processed. Yield and scrap require no further processing at the different reporting points. Therefore, only 11 units of the product (i.e., the WIP) remain to be processed: 3units 141 atRP A1 units 142 atRP A2 units 143 atRP A3 unit 144 atRP A4 104. The final yield (i.e., the finished product) of 13, the total scrap of 6, and the total work-in-process (WIP) of 11 equal the total order quantity of 30 according to this embodiment. -
FIG. 2 is a diagram depicting the merge order process according to one embodiment of the present invention. The first step in the process for merging orders is to “Receive Request to Merge Orders” 201. The request may be received in any number of ways according to various embodiments of the present invention. In the example embodiment, the request is received from the customer placing the order through a flexible order transaction system, a software application allowing flexible orders to be placed including the merging of production orders already in progress. The request to merge the orders does not need to specify the quantity to be merged and may only need to specify the merging order and the surviving order. The quantity to be merged can be determined from the merging order even though it may be specified in the merge order request. In an alternative embodiment of the present invention, the merge order process described herein can be used to transfer partial quantity from a merging order with a surviving order, the merging order continuing to exist after the partial quantity is transferred. According to this embodiment, the user (e.g., the customer) may specify the partial quantity to be transferred as well as the merging (source) order and surviving (receiving) order. - In the “Determine Quantities”
step 202, the quantities for each reporting point of the merging order are determined. According to this step, the yield, scrap, and work-in-process (WIP) are calculated at each reporting point in the process for the merging order. For example, using the information provided inFIG. 1 where Order_A is a merging order, reporting points A1-A4 101-104 exist for the process used to implement Order_A. At reporting point A1 1101, the following quantities of the product are determined: 24 units ofyield scrap WIP 141 all equaling the 30units 100 requested in the original order. Atreporting point A2 102, the following quantities of the product are determined: 18 units ofyield scrap WIP 123 all equaling the 24 units ofyield 111 ready for further processing afterRP A1 101. Atreporting point A3 103, the following quantities of the product are determined: 14 units ofyield scrap WIP 143 all equaling the 18 units ofyield 112 ready for further processing afterRP A2 102. Atreporting point A4 104, the following quantities of the product are determined: 13 units ofyield 114, no units ofscrap WIP 144 all equaling the 14 units ofyield 113 ready for further processing afterRP A3 103. - In the “Map Reporting Points”
step 203, mapping data between the reporting points of the processes corresponding to the merging order(s) (e.g., Order_B) and the surviving order (e.g., Order_A) is determined. The mapping data may be determined in different ways according to various embodiments of the present invention. In one embodiment, the mapping data may be determined by retrieving mapping data already stored for the processes. For example, data from a mapping table containing the reporting point mapping between the processes associated with the merging order, e.g., Order_B, and the surviving order, e.g., Order_A, may be retrieved. In another embodiment, a user may specify the mapping data when the merging of the orders is requested. For example, when the user enters the merge order request using flexible order transaction software running on a computing device such as a computer, the user may specify that reporting points B1, B3, and B6 in the merging order correspond to reporting points A1, A2, and A4 respectively in the surviving order. In another embodiment of the present invention, the mapping data may be calculated using other variables to determine at which reporting points similar processing has occurred. - The mapping data does not need to include mapping from all the reporting points in the process associated with the merging order to corresponding reporting points in the process associated with the surviving order, according to this embodiment—though all reporting points may be mapped. For example, the mapping between a merging order, e.g., Order_B, with associated reporting points B1-B6 may only map 3 of the reporting points (e.g., B1, B3, and B6) with a surviving order, e.g., Order_A. Just as all the reporting points in the process associated with the merging order do not need to be mapped, all the reporting points in the process associated with the surviving order also do not need to be mapped to the merging order. For example, a surviving order, e.g., Order_A, with associated reporting points A1-A4 may only have 3 reporting points mapped to the merging order, e.g., Order_C. In one embodiment of the present invention, two or more reporting points associated with a merging order (e.g., Order_D) may be mapped to a single reporting point associated with a surviving order (e.g., Order_A). This may occur where the additional processing for the second reporting point in the merging order (e.g., Order_D) does not add anything above the processing for the first reporting point in the merging order in relation to the processing that needs to occur in the surviving order (e.g., Order_A). For example, under these circumstances, reporting points D2 and D3 associated with a merging order, Order_D, may be mapped to a single reporting point A3 associated with a surviving order, Order_A. In one embodiment of the present invention, a single reporting point associated with a merging order (e.g., Order_E) may be mapped to two or more reporting points associated with a surviving order (e.g., Order_A). For example, reporting point E3 associated with a merging order, Order_E, may be mapped to reporting points A3 and A4 associated with a surviving order, Order_A. The above examples help illustrate the implementation of mapping in various embodiments of the present invention. Any conventional mapping means may be used to determine and supply the mapping data required.
- In the “Merge Mapped Quantities”
step 204, yield (i.e., the successfully processed units), scrap (i.e., the unsuccessfully processed units that can't be reworked), and the WIP (i.e., units awaiting or undergoing processing) are transferred from the merging order (e.g., Order_B) to the surviving order (e.g., Order_A) at each mapped reporting point. For example, if reporting points B1, B3, and B6 associated with Order_B (the merging order) are mapped respectively to reporting points A1, A2, and A4 associated with Order_A (the surviving order), yield, scrap, and WIP are transferred from Order_B to Order_A at each of these mapped reporting points. Yield, scrap, and WIP are therefore transferred between the mapped reporting point pairs: RP B1-RP A1, RP B3-RP A2, and RP B6-RP A4. The component and resource usage for the yield and scrap transferred at the mapped reporting points is also transferred to the surviving order. - In the “Merge Unmapped Quantities”
step 205, WIP, scrap, and the component and resource usage from non-mapped reporting points in the merging order (e.g., Order_B) are also transferred to the surviving order (e.g., Order_A) at the next mapped reporting point according to one embodiment in the present invention. This embodiment is a “soft down” transfer of unmapped quantities of WIP and scrap. If there are no further mapped reporting points between the merging and surviving orders, the non-mapped quantities are transferred to the last reporting point in the surviving order according to one embodiment of the present invention. In an alternative embodiment of the present invention, WIP, scrap, and the component and resource usage from non-mapped reporting points in the merging order are transferred to the surviving order at the next preceding mapped reporting point in the production process. This alternative embodiment is a “soft up” transfer of unmapped quantities of WIP and scrap. If there are no preceding mapped reporting points between the merging and surviving orders, the non-mapped quantities are transferred to the first reporting in the surviving order according to one embodiment of the present invention. - The steps described above are illustrative of the process and they can be performed in a different sequence, as necessary. In particular, according to one embodiment of the present invention, the steps of “Merge Mapped Quantities” 204 and “Merge Unmapped Quantities” 205 can be performed simultaneously or in sequence for each of the reporting points between a merging order and the surviving order. In another embodiment, all the existing orders may be considered merging orders with a new surviving order created matching the process structure of one of the merging orders and receiving the yield, scrap, and WIP from the merging orders.
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FIG. 3 is a diagram illustrating the merging of three orders according to one embodiment of the present invention. According to the example embodiment shown inFIG. 3 , two merging orders,Order_B 300 b andOrder_C 300 c, are merged with the surviving order, Order_A, 300 a, 300 m. The survivingOrder_A units 300 a before the merging of the orders. The merging of the orders combines their placed quantities creating a post-merge quantity of 30units 300 m in the survivingorder 300 m. The original order quantities and the resulting post-merge surviving order quantity are reflected as follows:Original (Pre-Merge) Resulting (Post-Merge) Order Quantity Order Quantity Order_A 10 30 Order_B 10 — Order_C 10 —
According to the example shown inFIG. 3 , yield, scrap, and WIP are transferred from the merging orders,Order_B 300 b andOrder_C 300 c, to the surviving order,Order_A 300 m. In an alternative embodiment, a new surviving order is created and all the original orders are merged into the new order and then deleted. The implementation of the merge according to the embodiment depicted inFIG. 3 depends on the mapping between reporting points of the orders and is outlined below. - In the example embodiment shown in
FIG. 3 , yield, scrap, and WIP are transferred from the merging orders,Order_B 300 b andOrder_C 300 c, to the survivingOrder_A Order_B 300 b andOrder_C 300 c, and the reporting points associated with the survivingOrder_A reporting point B1 yield scrap 361 s (which can't be reprocessed), and 1 unit of work-in-process (WIP) 361 w are available. Theyield 361,scrap 361 s, andWIP 361 w atRP B1 351 equal thetotal order quantity 300 b of 10 units for Order_B.Reporting point B1 351 maps toreporting point A1 301 in the surviving order. Atreporting point A1 yield scrap WIP 331 p exist before the merge (i.e., pre-merge). Thisyield 311 p,scrap 321 p, andWIP 331 p atRP A1 301 equal thetotal order quantity 300 a of 10 units for Order_A before the merge. According to the embodiment shown inFIG. 3 , all quantities are transferred from the merging order to the surviving order at the mapped reporting points. For example, a yield of 7units 361, a scrap of 2units 361 s, and a WIP of 1unit 361 w atRP B1 351 are transferred toRP A1 301 and added to theyield 311 m,scrap 321 m, and WIP 331 m. In addition, the component (BC1 and resource (BR1)usage 361 c atRP B1 351 is also transferred toRP A1 301.Reporting point B2 352 has a yield of 6units 362, a scrap of 1unit 362 s, and a WIP of 0units 362 w but is not mapped to Order_A 300 a, 300 m. Theyield 362,scrap 362 s, andWIP 362 w atRP B2 352 equal the yield of 7units 361 from the previous reportingpoint RP B1 351.Reporting point B3 353 has a yield of 5units 363, a scrap of 0units 363 s, and a WIP of 1unit 363 w equaling the yield of 6units 362 at the previous reportingpoint RP B2 352.RP B3 353 is mapped toRP A2 302 ofOrder_A yield 363,scrap 363 s, andWIP 363 w are transferred and added to the existing pre-merge yield of 6units 312 p, scrap of 0units 322 p, and WIP of 2units 332 p atRP A2 302. According to the embodiment depicted inFIG. 3 , thescrap 362 s andWIP 362 w of any unmapped preceding reporting points (in this case RP B2 352) are also transferred. Therefore, an additional scrap of 1unit 362 s and a WIP of 0units 362 w is also transferred fromRP B2 352 at the next mapped reportingRP B3 353 toRP A2 302. Unmapped yield is not transferred according to this embodiment, only unmapped scrap and WIP. The component (B3) and resource (BR3)usage 363 c at the mappedreporting point 353 and component (BC2) and resource (BR2)usage 362 c at any precedingunmapped reporting point 352 are also transferred toRP A2 302.Reporting point B4 354 has a yield of 5units 364, a scrap of 0units 364 s, and a WIP of 0units 364 w totaling the 5 units ofyield 363 at theprevious RP B3 353.RP B4 354 is not mapped to Order_A 300 a, 300 m.Reporting point B5 355 has a yield of 4units 365, a scrap of 1unit 365 s, and a WIP of 0units 365 w totaling the 5 units ofyield 364 at theprevious RP B4 354.RP B5 355 is not mapped to Order_A 300 a, 300 m.Reporting point B6 356 has a yield of 3units 366, a scrap of 0units 366 s, and a WIP of 1unit 366 w totaling the 4 units ofyield 365 at theprevious RP B5 355.RP B6 356 is mapped toRP A4 304 inOrder_A yield 366,scrap 366 s, andWIP 366 w are transferred and added to the yield of 2units 314 p, scrap of 0units 324 p, and WIP of 2units 334 p that exist atRP A4 304 prior to the merge. As previously stated, preceding unmapped scrap and WIP are also transferred according to this embodiment of the present invention. At precedingRP B4 354, there is noscrap 364 s (0 units) and noWIP 364 w (0 units) to transfer. At precedingRP B5 355, there is 1 unit ofscrap 365 s and noWIP 365 w (0 units) to transfer toRP A4 304. In addition, the component (BC6) and resource (BR6)usage 366 c from the mappedreporting point 356 and the component (BC4, BC5) and resource (BR4, BR5)usage RP A4 304. - The other merging order is
Order_C 300 c. At the firstreporting point C1 381, a yield of 9units 391, a scrap of 1unit 391 s, and a WIP of 0units 391 w total the placed order quantity of 10units 300 c.RP C1 381 is not mapped to the survivingOrder_A Reporting point C2 382 has a yield of 6units 392, a scrap of 1unit 392 s, and a WIP of 2units 392 w totaling theyield 391 of 9 units at the precedingRP C1 381.RP C2 382 is mapped toRP A1 301 and, therefore, theyield 392,scrap 392 s, andWIP 392 w are transferred and added toRP A1 301. As previously stated, any preceding unmapped scrap and WIP are also transferred according to this embodiment. The scrap of 1unit 391 s and noWIP 391 w (0 units) are also transferred fromRP C1 381 toRP A1 301. In addition, the component (CC2) and resource (CR2)usage 392 c from the mappedreporting point 382 and the component (CC1) and resource (CR1)usage 391 c from any unmapped preceding reporting points 381 are also transferred toRP A1 301.Reporting point C3 383 has a yield of 5units 393, a scrap of 1unit 393 s, and a WIP of 0units 393 w totaling the yield of 6units 392 at the precedingRP C2 382.RP C3 383 is not mapped to the survivingOrder_A Reporting point C4 384 has a yield of 4units 394, a scrap of 0units 394 s, and a WIP of 1unit 394 w totaling the 5 units ofyield 393 at the precedingRP C3 383.RP C4 384 is mapped toRP A3 303 and, therefore, theyield 394,scrap 394 s, andWIP 394 w are transferred. In addition, the scrap (1unit 393 s) and WIP (0units 393 w) from any preceding unmapped reporting points 383 are also transferred—in this case fromRP C3 383. Additionally, the component (CC4, CC3) and resource (CR4, CR3)usage reporting point 384 and any preceding unmapped reporting points 383 are also transferred toRP A3 303.Reporting point C5 385 has yield of 4units 395, a scrap of 0units 395 s, and a WIP of 0units 395 w totaling the yield of 4units 394 at the precedingRP C4 394.RP C5 385 is not mapped to the survivingOrder_A Reporting point C6 386 has a yield of 1unit 396, noS scrap 396 s, and a WIP of 3units 396 w totaling the yield of 4units 395 at the precedingRP C5 385.RP C6 386 is mapped toRP A4 304 and, therefore, theyield 396,scrap 396 s, andWIP 396 w are transferred. According to this embodiment, the scrap (0units 395 s) and the WIP (0units 395 w) from any preceding unmapped reporting points 385 are also transferred—in this case fromRP C5 385. Component (CC6, CC5) and resource (CR6, CR5)usage reporting point 386 and any preceding unmapped reporting points 385 are also transferred toRP A4 304. - The end result of the merging process is that all the yield, scrap, WIP, and component and resource usage is transferred from the merging orders to the surviving order according to one embodiment of the present invention. In the example embodiment depicted in
FIG. 3 , atRP A1 301, the original pre-merge yield of 8 units 31 p is increased by 7units 361 fromRP B1 units 392 fromRP C2 382 resulting in a post-merge yield of 21units 311 m. The pre-merge scrap of 1unit 321 p is increased by the 2units 361 s fromRP B1 unit 392 s fromRP C2 unit 391 s fromRP C1 381 resulting in a post-merge scrap of 5units 321 m. The pre-merge WIP of 1unit 331 p is increased by 1unit 361 w fromRP B1 units 392 w fromRP C2 units 391 w fromRP C1 381 resulting in a post-merge WIP of 4 units 331 m. Component andresource usage RP B1 351,RP C2 382, andRP C1 381 and added to the component (AC1) and resource (AR1) usage 341 atRP A1 301. - At
reporting point A2 302, the pre-merge yield of 6units 312 p is increased by 5units 363 fromRP B3 353. Because there is no mapping betweenRP A2 302 and mergingOrder_C 300 c, the previously transferred yield of 6units 392 continues atRP A2 302 for themerged Order_C 300 c according to one embodiment of the present invention. The end result is a post-merge yield of 17units 312 m. The pre-merge scrap of 0units 322 p is increased by 0units 363 s fromRP B3 unit 362 s fromRP B2 352 resulting in a post-merge scrap of 1unit 322 m.Order_C 300 c does not map toRP A2 302 and does not, therefore, alter the scrap or WIP atRP A2 302. The pre-merge WIP of 2units 332 p is increased by 1unit 363 w fromRP B3 units 362 w fromRP B2 352 resulting in a post-merge WIP of 3 units 332 m. Component andresource usage RP B3 353 andRP B2 352 and added to the component (AC2) and resource (AR2) usage 342 atRP A2 302. - At
reporting point A3 303, the pre-merge yield of 4 units 313 p is increased by 4units 394 fromRP C4 384. Because there is no mapping betweenRP A3 303 and mergingOrder_B 300 b, the previously transferred yield of 5units 363 fromRP B3 353 continues atRP A3 303 for themerged Order_B 300 b according to one embodiment of the present invention. The end result is a post-merge yield of 13 units 313 m. The pre-merge scrap of 1 unit 323 p is increased by 0units 394 s fromRP C4 unit 393 s fromRP C3 383 resulting in a post-merge scrap of 2units 323 m.Order_B 300 b does not map toRP A3 303 and does not, therefore, alter the scrap or WIP atRP A3 303. The pre-merge WIP of 1unit 333 p is increased by 1unit 394 w fromRP C4 units 393 w fromRP C3 383 resulting in a post-merge WIP of 2 units 333 m. Component andresource usage RP C4 384 andRP C3 383 and added to the component (AC3) and resource (AR3)usage 343 atRP A3 303. - At
reporting point A4 304, the pre-merge yield of 2units 314 p is increased by 3units 366 fromRP B6 unit 396 fromRP C6 386 resulting in a post-merge yield of 6units 314 m. The pre-merge scrap of 0units 324 p is increased by 0units 366 s fromRP B6 unit 365 s fromRP B5 units 364 s fromRP B4 units 396 s fromRP C6 units 395 s fromRP C5 385 resulting in a post-merge scrap of 1unit 324 m. The pre-merge WIP of 2units 334 p is increased by 1unit 366 w fromRP B6 units 365 w fromRP B5 units 364 w fromRP B4 units 396 w fromRP C6 units 395 w fromRP C5 385 resulting in a post-merge WIP of 6 units 334 m. Component andresource usage RP B6 356,RP B5 355,RP B4 354,RP C6 386, andRP C5 385 and added to the component (AC4) and resource (AR4)usage 344 atRP A4 304. - In other embodiments of the present invention, it may be possible to decrease or increase the total order quantity for the surviving order during the merging process. For example, if the merging orders and the pre-merge surviving order have a total placed order quantity of 30, the resulting surviving order may be placed for a quantity greater than 30. The additional quantity may result in additional WIP at the initial reporting point in the surviving order. In another embodiment, the order quantity may be reduced during the merging process. For example, if the merging orders and the pre-merge surviving order have a total placed order quantity of 30, the resulting surviving order may be placed for a quantity less than 30. The decreased quantity may result from eliminating WIP or reducing order quantity to reflect scrap at the initial reporting point in the surviving order.
- In the example embodiment depicted in
FIG. 3 , scrap, WIP, and component and resource usage from unmapped reporting points in the merging orders were transferred to the surviving order at the next or subsequent mapped reporting point. This process may be referred to as “soft down” merging. According to one embodiment of the present invention, if there is no subsequent mapped reporting point, scrap, WIP, and/or component and resource usage may be merged with the surviving order at the final reporting point in the surviving order. In another embodiment of the present invention, WIP, scrap, and/or component and resource usage at an unmapped reporting point may be merged with the surviving order at the first earlier or preceding mapped reporting point. If there is no preceding mapped reporting point, WIP, scrap, and/or component and resource usage may be merged with the surviving order at the first reporting point in the surviving order. This process may be referred to as “soft up” merging. In one embodiment, the merging of WIP, scrap, and/or component and resource usage at the final reporting point in a merging order is always made to the final reporting point in the surviving order regardless of whether “soft up” or “soft down” merging is being used. -
FIG. 4 is a diagram illustrating the process of merging WIP, scrap, and component and resource usage from unmapped reporting points at the first preceding mapped reporting point according to one embodiment of the present invention. The example embodiment shown inFIG. 4 is similar to the example shown inFIG. 3 except that the unmapped reporting point values inOrder_B 300 b andOrder_C 300 c are merged with the preceding mapped reporting points (or the first reporting point) thereby changing the post-merge yield, scrap, and WIP values in the survivingOrder_A 300 m as well as the distribution of component and resource usage. One notable change in the example embodiment depicted inFIG. 4 is the decrease in the post-merge yield by 2 units 411 m atRP A1 301 and the increase in 2 units of post-merge scrap 421 m reflecting a decrease in the mapped yield by the subsequent unmapped scrap that is transferred at this preceding reporting point. These changes are further reflected in modifications to the yield 412 m, 413 m and the scrap 423 m, 424 m at the subsequent reporting points A2-A4 302-304 in the surviving order.
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